Container with Improved Content Material Release Opening

ABSTRACT

A container having a compose content material release opening formed from a wall having a major opening and a flap having one or more smaller flap edge openings.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority to U.S. Provisional Application Ser. No. 60/934,434, filed on Jun. 13, 2007, which is hereby incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to containers with a novel content material release opening.

2. Description of Related Art

Many different containers are found in the prior art which are designed to dispense granular materials held therewithin, with the type of granular material ranging from coarse granular material such as coarse sea salt to finer granular material such as baby powder, baking soda, or other such fine granular materials. The number of different types of dispensing openings used in the prior art to dispense the granular materials is quite large, to say the least. For example, there are pour spouts, funnels, basic openings in the walls of the container, and many other types of dispensing openings. However, the vast majority of these dispensing openings are designed to release granular material in quantity, but are not well-suited to “sprinkling” granular material such as artificial sweetener, salt, or the like onto foodstuffs or liquids for flavoring thereof. Therefore, there is a need for a container having a dispensing opening which is capable of sprinkling the granular material to control the dispensing of the granular material from the container.

Of course, it is true that there are many different sprinkling-type dispensing openings found in the prior art, but in general these all include some type of opening having a rigid cover having a plurality of smaller openings formed therein, as is found in a salt shaker or the like. The problem with these types of dispensing containers is that they cannot be assembled by standard carton assembly machines and the container generally cannot be formed from a single blank of material, thereby requiring additional assembly steps and therefore increasing the production cost of the container. There is therefore a need for a container having a dispensing opening which is capable of sprinkling the granular material from the container and which is constructed in such a fashion that it can be manufactured by standard carton blank manufacturing devices and moreover can be assembled by standard carton assembly machines.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to containers having a novel content material release opening. The invention is particularly useful for gradually sprinkling or otherwise releasing granular materials from the container.

In one aspect, a wall of the container is combined with a standard flap (such as a dust flap or glue flap) in order to form a composite content material release opening. The flap includes one or more small openings along its edge. These small edge openings can be manufactured much more easily compared to a small punch hole, which often becomes stuck in the container material (similar to a card hole aggregate debris or “chad”).

In one aspect, the container is formed using a novel box blank. The box blank generally comprises a top wall panel, a bottom wall panel, and a plurality of side wall panels. A major opening is formed in one of the wall panels. The box blank also comprises a flap having a flap edge with at least one flap edge opening. The flap is configured so that the at least one flap edge opening may be aligned with the major opening in the wall panel to form a composite content material release opening.

In yet another aspect, the major opening is formed in a wall panel selected from the group consisting of the top wall panel, the bottom wall panel, or a side wall panel. In still a further aspect, the major opening comprises a foldable flap in one of the wall panels. The foldable flap may extend to an edge of the wall panel. In another aspect, the opening comprises a hole in one of the wall panels.

In another aspect, the flap edge has a plurality of flap edge openings. The flap edge openings may be any suitable shape or size, but preferably comprises a rectangular slot.

The present invention is also directed to a one-piece box formed of foldable material formed using the box blank as discussed above. A sticker with pressure sensitive adhesive may be optionally used to cover at least a portion of composite content material release opening formed by the flap edge openings and the major opening in the wall.

Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the container box in accordance with a first embodiment of the present invention.

FIG. 2 is a top plan view of the carton blank shown in FIG. 1 prior to assembling the container box of the present invention.

FIG. 3 is a top plan view of the assembled box shown in FIG. 1 showing how the glue flap extends behind the side wall.

FIG. 4 is a perspective view of the container box in accordance with a second embodiment of the present invention.

FIG. 5 is a top plan view of the carton blank shown in FIG. 4 prior to assembling the container box of the present invention.

FIG. 6 is a perspective view of the container box in accordance with a third embodiment of the present invention.

FIG. 7 is a top plan view of the carton blank shown in FIG. 6 prior to assembling the container box of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The present invention is directed to novel containers, novel blanks for making the containers, and methods of making the containers. The container is generally comprised of three or more side walls, and typically comprises both a top wall and a bottom wall. In addition, the container has at least one flap, such as a dust flap or glue flap. At least one of the walls of the container has a major opening covered at least in part by the flap. The flap has an edge with at least one flap edge opening therein so that together the major opening in the wall and the flap edge opening form a composite content material release opening. In one aspect, the major opening is formed in a side wall of the container, and a side glue flap covers at least a portion of the major opening to form the composite content release opening. In another aspect, the major opening is formed in a top wall of the container, and a top glue flap covers at least a portion of the major opening to form the composite content release opening. It will be appreciated to those skilled in the art that other flap and wall combinations (side walls, top wall, bottom wall, etc.) may be used to form the composite content release opening by making modifications to the teachings and various embodiments discussed herein.

The composite content release opening is preferably resealable. In one aspect, a foldable flap used to form the major opening in the container wall resealably covers the opening by frictionally engaging the periphery of the major opening. In another aspect, the foldable flap used to form the major opening removably engages one or more slots in the glue flap to resealably cover the composite content release opening. Further, a sticker having pressure sensitive adhesive can be optionally applied to reseal the composite content release opening.

Although specific exemplary embodiments are discussed herein, it will be readily appreciated that the flap edge openings and the major opening in the wall may combine to form many different arrangements and types of composite content material release openings. However, when dispensing granular material, it is generally preferred that the composite content material release opening formed by the interaction of the flap edge openings and the major opening in the wall be generally rounded rectangles in shape. The exact shape of the composite content material release opening is not particularly critical to the present invention so long as the dispensing of the contents of the container is facilitated. Typically, the flap edge openings have dimensions on the order of 5, 4, 3, 2, or 1 mm, or less.

Further, one of the advantageous features of the present invention is that the major opening in the wall can be easily formed during the manufacturing process. Similarly, the flap edge openings in the glue or dust flap may likewise be die cut from the sheet of construction material from which the box blank is being removed merely by using slightly modified die cut machines already used in the packaging industry. This means that the container of the present invention can be manufactured and assembled without requiring large-scale transformations of already existing equipment. In fact, as virtually all other granular dispensing containers include elements which must be added to the container after manufacturing or require punching of small holes through the material, the production of these prior art containers is more time-consuming and labor-intensive than the production of the present invention. Therefore it is believed that the present invention provides a significant improvement over those prior art containers.

First Embodiment

Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 illustrates a container having a composite content material release opening formed from the box blank illustrated in FIG. 2. The blank 50 is constructed of a generally planar, sheet-like material which is separated into a plurality of panels by a plurality of fold lines 13. It should be noted that the fold lines 13 may represent physical areas of weakness prone to folding, for example by having been scored or pre-folded, or they may simply be virtual lines along which folds take place during a manufacturing process. Non-limiting examples of suitable materials include paper, paperboard, plastic, fabrics, and sheet metal. In the illustrated example, the blank is constructed from paperboard.

FIGS. 1 and 3 illustrate a container 10 and corresponding container blank 50 in accordance with a first embodiment of the present invention. The container 10 is a generally rectangular box 12, which includes a top wall 14, bottom wall 16, side walls 18 a and 18 b, and side walls 20 a and 20 b. As shown in FIG. 2, the box blank 50 comprises various panels which correspond to the top wall 14, bottom wall 16, side walls 18 a and 18 b, and side walls 20 a and 20 b. The box blank 50 also illustrates additional top and bottom gluing or dust flaps 22 a-d and side glue flap 24 which facilitate assembly of the container 10.

The container 10 is of general standard design and construction. However, in this embodiment of the present invention, side wall 20 a includes a major opening 30. The major opening 30 is preferably a generally rectangular, oval or circular opening formed in side wall 20 a and extending therethrough, as shown best in FIGS. 1 and 2. This major opening 30 is formed by punching out or die cutting the specific section of side wall 20 a during the manufacturing process. In this embodiment, the major opening is formed by making a foldable flap 40 in side wall 20 a.

As shown in FIGS. 2 and 3, side glue flap 24 is connected to and extends outward from side wall 18 b. The side glue flap 24 has a flap edge 26 having a plurality of flap edge openings 28 extending into the side glue flap 24 from the flap edge 26. The flap edge openings 28 are generally rectangular in shape with rounded inner edges. The specific shape of the flap edge openings 28 may be modified or changed depending on the content material to be released from container 10 and the desired flow rate for the content material. The side glue flap 24 preferably has a width so that the flap edge 26 is aligned with or extends slightly beyond the edge of the major opening 30 of the side wall 20 a as shown in FIG. 3. In this embodiment, the side glue flap 24 has a width of at least one-half of the side wall 20 a in order to properly position the flap edge openings 28 behind the major opening 30 when the side glue flap 24 is affixed to the side wall 20 a.

As shown in FIG. 3, when the side glue flap 24 is placed in parallel alignment behind the side wall 20 a in preparation for assembly of the container 10, the width of the side glue flap 24 positions the flap edge openings 28 in alignment with and directly behind the major opening 30 with the flap edge 26 of the side glue flap 24 preferably being positioned just beyond the major opening 30. The glue flap 24 thus covers and closes a large portion of the major opening 30 with the only open portions remaining in the major opening 30 being those corresponding with the flap edge openings 28 of the side glue flap 24. The side glue flap 24 is then secured to the side wall 20 a as shown in FIG. 3 by at least one line of glue or other adhesive (or using other sealing means, such as heat sealing as is known in the art) which is placed on the outer face of the side glue flap 24 then is pressed into contact with the side wall 20 a. The container 10 is thus assembled in the form shown in FIG. 1. Together, the major opening 30 formed in the side wall 20 a of the container and the flap edge openings 28 in the side glue flap 24 form a composite content release opening.

In this embodiment, the major opening 30 is covered by a resealable flap 40 which is hingedly connected to the side wall 20 a via fold line 42. The resealable flap 40 is operative to resealably cover the major opening 30 and thus the flap edge openings 28 to alternatively prevent and permit dispensing of the contents of the container (typically granular material) through the flap edge openings 28 and the major opening 30. Optionally, a sticker having pressure sensitive adhesive (not shown) may be applied over at least a portion of the resealable flap 40 in order to assist with closure of the flap.

Second Embodiment

FIGS. 4 and 5 illustrate a container 1 10 and corresponding container blank 150 in accordance with a second embodiment of the present invention. The container 10 is a generally rectangular box 112, which includes atop wall 114, bottom wall 116, side walls 118 a and 118 b, and side walls 120 a and 120 b. As shown in FIG. 5, the box blank 150 comprises various panels which correspond to the top wall 114, bottom wall 116, side walls 11 8 a and 118 b, and side walls 120 a and 120 b. The box blank 150 also illustrates additional top and bottom gluing or dust flaps 122 a-d and side glue flap 124 which facilitate assembly of the container 110.

The container 110 is of general standard design and construction. However, in this embodiment of the present invention, top wall 114 includes a major opening 130. The major opening 130 is preferably generally rectangular, oval, or circular opening formed in top wall 114 and extending therethrough. This major opening 130 is formed by punching out or die cutting the specific section of top wall 114 during the manufacturing process. In this embodiment, the major opening is formed by making a hole in top wall 114.

Top glue flap 122 b is connected to and extends upward from side wall 120 b. The top glue flap 122 b has a flap edge 126 having a flap edge opening 128 extending into the top glue flap 122 b from the flap edge 126. The flap edge opening 128 is a generally semi-circle opening. The specific shape of the flap edge opening 128 may be modified or changed depending on the content material to be released from container 110 and the desired flow rate for the content material. The top glue flap 122 b preferably has a width so that the flap edge 126 is aligned with or extends slightly beyond the edge of the major opening 130 of the top wall 114.

When the top glue flap 122 b is placed in parallel alignment behind the top wall 114 in preparation for assembly of the container 110, the width of the top glue flap 122 b positions the flap edge opening 128 in alignment with and directly behind the major opening 130 with the flap edge 126 of the top glue flap 122 b being preferably positioned beyond the major opening 130. The top glue flap 122 b thus covers and closes a large portion of the major opening 130 with the only open portions remaining in the major opening 130 being those corresponding with the flap edge opening 128 of the top glue flap 114. The top glue flap 122 b is then secured to the top wall 114 by at least one line of glue or other adhesive (or using other sealing means, such as heat sealing as is known in the art) which is placed on the outer face of the side glue flap 122 b then is pressed into contact with the top wall 114. The container 110 is thus assembled in the form shown in FIG. 4. Together, the major opening 130 formed in the top wall 114 of the container and the flap edge opening 128 in the top glue flap 122 b form a composite content release opening.

In this embodiment, the major opening 130 is covered by a sticker having pressure sensitive adhesive on its periphery (not shown). The sticker is operative to resealably cover the major opening 130 and thus the flap edge opening 128 to alternatively prevent and permit dispensing of the contents of the container (typically granular material) through the flap edge opening 128 and the major opening 130.

Third Embodiment

FIGS. 6 and 7 illustrate a container 310 and corresponding container blank 350 in accordance with a third embodiment of the present invention. The blank 350 is similar in design to that of the first embodiment. Again, the container 310 is a generally rectangular box 312, which includes a top wall 314, bottom wall 316, side walls 318 a and 318 b, and side walls 320 a and 320 b. As shown in FIG. 7, the box blank 350 comprises various panels which correspond to the top wall 314, bottom wall 316, side walls 318 a and 318 b, and side walls 320 a and 320 b. The box blank 50 also illustrates additional top and bottom gluing or dust flaps 322 a-d and side glue flap 324 which facilitate assembly of the container 310.

In this embodiment of the present invention, side wall 320 a includes a major opening 330. The major opening 330 is preferably a generally rectangular opening formed in side wall 320 a and to the edge of the side all 320 a. This major opening 330 is formed by punching out or die cutting the specific section of side wall 320 a during the manufacturing process. In this embodiment, the major opening is formed by making a foldable flap 340 in side wall 320 a, in which the foldable flap 340 extends to the edge of the side wall 320 a.

As shown in FIGS. 6 and 7, side glue flap 324 is connected to and extends outward from side wall 318 b. The side glue flap 324 has a flap edge 326 having a plurality of flap edge openings 328 extending into the side glue flap 324 from the flap edge 326. The flap edge openings 328 are generally rectangular in shape with rounded inner edges. The specific shape of the flap edge openings 328 may be modified or changed depending on the content material to be released from container 3 10 and the desired flow rate for the content material. The side glue flap 324 preferably has a width so that the flap edge 326 is aligned with or extends slightly beyond the edge of the major opening 330 of the side wall 320 a. In this embodiment, the side glue flap 324 has a width of at least one-half of the side wall 320 a in order to properly position the flap edge openings 328 relative to the major opening 330 when the side glue flap 324 is affixed to the side wall 320 a. The glue flap also has at least one slot 329 for receiving the foldable flap 340.

The container is assembled in a manner similar to the container described in the first embodiment. When the side glue flap 324 is placed in parallel alignment behind the side wall 320 a in preparation for assembly of the container 310, the width of the side glue flap 324 positions the flap edge openings 328 in alignment with and positioned directly behind the major opening 330 with the flap edge 326 of the side glue flap 324 being preferably positioned beyond the major opening 330. The glue flap 324 thus covers and closes a large portion of the major opening 330 with the only open portions remaining in the major opening 330 being those corresponding with the flap edge openings 328 of the side glue flap 324. The side glue flap 324 is then secured to the side wall 320 a by at least one line of glue or other adhesive (or using other sealing means, such as heat sealing as is known in the art) which is placed on the outer face of the side glue flap 324 then is pressed into contact with the side wall 320 a. The container 10 is thus assembled in the form shown in FIG. 6. Together the major opening 330 formed in the side wall 320 a of the container and the flap edge openings 328 in the side glue flap 324 form a composite content release opening.

In this embodiment, however, the major opening 330 is covered by a resealable flap 340 which is hingedly connected to the side wall 320 a via fold line 342. The resealable flap 340 removably engages one or more corresponding cuts or slots 329 in the side glue flap 324, preferably by folding the resealable flap 340 along the dashed fold line 343 shown in FIG. 6. Thus, the resealable flap 340 is operative to resealably cover the major opening 330 and thus the flap edge openings 328 to alternatively prevent and permit dispensing of the contents of the container (typically granular material) through the flap edge openings 328 and the major opening 330.

It is to be understood that numerous additions, substitutions, and modifications may be made to the container of the present invention which fall within the intended broad scope of the above description. For example, the size, shape, and construction materials used in the construction of the various elements of the present invention may be modified or changed so long as the functionality of the invention is neither degraded nor destroyed. Also, it should be noted that although the present invention has been described as being used with granular materials, it is entirely possible that the present invention may be used with other materials which will be determined by the end user of the container. Finally, the location and arrangement of the various openings such as the major opening, and the flap edge openings, may be moved, modified, or changed to any of the top wall, bottom wall, side walls, and such modifications should be understood to be a part of this disclosure.

From the foregoing it will be seen that this invention is one well adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative, and not in a limiting sense. While specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. 

1. A box blank comprising: a top wall panel; a bottom wall panel; a plurality of side wall panels, said plurality of side wall panels comprising a first side wall panel a second side wall panel; a major opening in a wall panel, said major opening having a peripheral edge; a flap having a flap edge, said flap edge having at least one flap edge opening; said flap configured so that said at least one flap edge opening may be aligned with said major opening in said wall panel to form a composite content material release opening.
 2. The box blank of claim 1, wherein said major opening comprises a foldable flap in said first side wall panel.
 3. The box blank of claim 2, wherein said major opening comprises a foldable flap which extends to an edge of said first side wall panel.
 4. The box blank of claim 1, wherein said flap edge has a plurality of flap edge openings.
 5. The box blank of claim 1, wherein at least one flap edge opening comprises a rectangular slot.
 6. The box blank of claim 1, wherein said major opening is formed in said first side wall panel, and wherein said flap having said at least one flap edge opening is a side flap connected to said second side wall panel.
 7. The box blank of claim 1, wherein said major opening is formed in said top wall panel, and wherein said flap having said at least one flap edge opening is a top flap connected to said second side wall panel.
 8. A one-piece box formed of foldable material comprising: a top wall; a bottom wall; a plurality of side walls, said plurality of side walls comprising a first side wall and a second side wall; a major opening in a wall, said major opening having a peripheral edge; a flap having a flap edge, said flap edge having at least one flap edge opening; said flap configured so that said at least one flap edge opening is aligned with said major opening in said wall to form a composite content material release opening.
 9. The box of claim 8, wherein said major opening comprises a foldable flap in said first side wall.
 10. The box of claim 8, wherein said flap edge has a plurality of flap edge openings.
 11. The box of claim 8, wherein at least one flap edge opening comprises a rectangular slot.
 12. The box of claim 8, wherein said major opening is formed in said first side wall, and wherein said flap having said at least one flap edge opening is a side flap connected to said second side wall.
 13. The box of claim 8, wherein said major opening is formed in said top wall, and wherein said flap having said at least one flap edge opening is a top flap connected to said second side wall.
 14. The box of claim 8, further comprising a sticker having pressure sensitive adhesive covering at least a portion of said composite content material release opening. 